Semiconductor device and method for manufacturing the same

ABSTRACT

An insulating layer which releases a large amount of oxygen is used as an insulating layer in contact with a channel region of an oxide semiconductor layer, and an insulating layer which releases a small amount of oxygen is used as an insulating layer in contact with a source region and a drain region of the oxide semiconductor layer. By releasing oxygen from the insulating layer which releases a large amount of oxygen, oxygen deficiency in the channel region and an interface state density between the insulating layer and the channel region can be reduced, so that a highly reliable semiconductor device having small variation in electrical characteristics can be manufactured. The source region and the drain region are provided in contact with the insulating layer which releases a small amount of oxygen, thereby suppressing the increase of the resistance of the source region and the drain region.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No.13/185,779, filed Jul. 19, 2011, now allowed, which claims the benefitof a foreign priority application filed in Japan as Serial No.2010-167383 on Jul. 26, 2010, both of which are incorporated byreference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a semiconductor device and a method formanufacturing the semiconductor device.

In this specification, a semiconductor device means a general devicewhich can function by utilizing semiconductor characteristics, and anelectro-optic device, a semiconductor circuit, and an electronic deviceare all semiconductor devices.

2. Description of the Related Art

A technique by which transistors are formed using semiconductor thinfilms over a substrate having an insulating surface has been attractingattention. Such transistors are applied to a wide range of electronicdevices such as integrated circuits (ICs) or image display devices(display devices). A silicon-based semiconductor material is widelyknown as a material for a semiconductor thin film applicable to atransistor. As another material, an oxide semiconductor has beenattracting attention.

For example, a transistor whose active layer includes an amorphous oxidecontaining indium (In), gallium (Ga), and zinc (Zn) and having anelectron carrier concentration of less than 10¹⁸/cm³ is disclosed (seePatent Document 1).

A transistor including an oxide semiconductor is known to have a problemof low reliability because of high possibility of fluctuation inelectric characteristics, although the transistor including an oxidesemiconductor can operate at higher speed than a transistor includingamorphous silicon and can be manufactured more easily than a transistorincluding polycrystalline silicon. For example, the threshold voltage ofthe transistor fluctuates after a bias-temperature stress test (BTtest). Note that in this specification, a threshold voltage refers to agate voltage which is needed to turn on a transistor. A gate voltagerefers to a potential difference between a source electrode and a gateelectrode when the potential of the source electrode is used as areference potential.

REFERENCE [Patent Document]

-   [Patent Document 1] Japanese Published Patent Application No.    2006-165528

SUMMARY OF THE INVENTION

Fluctuation in the threshold voltage due to a BT test of the transistorincluding an oxide semiconductor remarkably reduces the reliability ofthe transistor including an oxide semiconductor. An object of oneembodiment of the present invention is to improve the reliability of asemiconductor device including an oxide semiconductor.

One embodiment of the present invention is a semiconductor device or amethod for manufacturing the semiconductor device, which is based on atechnical idea that an insulating layer from which oxygen is released byheating is used as an insulating layer in contact with a channel regionof an oxide semiconductor layer, and an insulating layer which releasesa smaller amount of oxygen than the insulating layer in contact with thechannel region is used as an insulating layer in contact with a sourceregion and a drain region of the oxide semiconductor layer.

One embodiment of the present invention is a semiconductor device or amethod for manufacturing the semiconductor device. The semiconductordevice includes an insulating layer including a first region and asecond region; and an oxide semiconductor layer which is in contact withthe first region and the second region and includes a channel region, asource region, and a drain region. The channel region of the oxidesemiconductor layer is in contact with the first region. The sourceregion and the drain region of the oxide semiconductor layer are incontact with the second region. The first region is an insulating layerfrom which oxygen is released by heating. The second region is aninsulating layer which releases a smaller amount of oxygen than thefirst region.

To release oxygen by heating means that the released amount of oxygenwhich is converted to oxygen atoms is greater than or equal to 1×10¹⁸atoms/cm³, preferably greater than or equal to 3×10²⁰ atoms/cm³ inthermal desorption spectroscopy (TDS).

Supply of oxygen to the channel region from the first region that is theinsulating layer in contact with the channel region can reduce aninterface state density between the channel region and the first region.As a result, it is possible to sufficiently suppress trapping of chargeor the like which can be generated due to the operation of asemiconductor device, or the like, at an interface between the firstregion and the channel region.

Further, charge is caused due to oxygen deficiency in the channel regionin some cases. In general, part of oxygen deficiency in a channel regionserves as a donor and generates electrons that are carriers. As aresult, the threshold voltage of the transistor shifts in the negativedirection. A sufficient amount of oxygen is released to the channelregion from the first region that is the insulating layer in contactwith the channel region, whereby oxygen deficiency in the channelregion, which causes the shift of the threshold voltage in the negativedirection, can be compensated.

In other words, when oxygen deficiency is caused in the channel region,it is difficult to suppress charge trapping at the interface between thechannel region and the first region that is an insulating layer incontact with the channel region. However, by providing an insulatinglayer from which oxygen is released by heating as the first region, theinterface state density between the channel region and the first regionand the oxygen deficiency in the channel region can be reduced, andinfluence by the charge trapping at the interface between the channelregion and the first region can be reduced.

In addition, the source region and the drain region are provided incontact with the second region which releases a smaller amount of oxygenthan the first region so that oxygen is not supplied to the sourceregion and the drain region. This structure is employed, consideringthat the part of oxygen deficiency in the oxide semiconductor layergenerates electrons that are carriers. In other words, this is based ona technical idea that is to suppress the increase of the resistance ofthe source region and the drain region which is caused by the reductionof oxygen deficiency by supply of oxygen. For example, an insulatinglayer which releases oxygen of less than 1×10¹⁸ atoms/cm³ in TDSanalysis can be used as the second region in contact with the sourceregion and the drain region.

Thus, the effect of one embodiment of the present invention isattributed to the insulating layer from which oxygen is released byheating and the insulating layer which releases a smaller amount ofoxygen than the insulating layer.

Owing to an effect of suppressing the charge trapping at the interfaceof the channel region of the oxide semiconductor layer and suppressingthe increase of the resistance of the source region and the drainregion, it is possible to suppress a malfunction such as the reductionof an on-state current of the transistor, to which the reduction ofcurrent flowing through the source region and the drain region incomparison with the channel region which is caused by the increase ofthe resistance of the source region and the drain region is attributed.In addition, a malfunction such as the increase of an off-state currentof the transistor including the oxide semiconductor and the shift of thethreshold voltage can be suppressed. Further, the reliability of thesemiconductor device can be improved.

Note that the insulating layer from which oxygen is released by heatingpreferably has an enough thickness with respect to the oxidesemiconductor layer. This is because when the thickness of theinsulating layer from which oxygen is released by heating is smallerthan that of the oxide semiconductor layer, oxygen is not sufficientlysupplied to the oxide semiconductor layer in some cases.

One embodiment of the present invention is a semiconductor device or amethod for manufacturing the semiconductor device. The semiconductordevice includes an insulating layer including a first region and asecond region; an oxide semiconductor layer which is provided in contactwith the first region and the second region and includes a channelregion, a source region, and a drain region; a gate insulating layer incontact with the oxide semiconductor layer; and a gate electrode incontact with the gate insulating layer. The channel region of the oxidesemiconductor layer is provided in contact with the first region. Thesource region and the drain region of the oxide semiconductor layer areprovided in contact with the second region. The first region is aninsulating layer from which oxygen is released by heating. The secondregion is an insulating layer which releases a smaller amount of oxygenthan the first region. Note that the first region may be formed using amaterial having constituent elements which are the same or differentfrom those of the material of the second region or a material whose twoor more constituent elements are the same as those of the material ofthe second region.

In the above structure, the insulating layer from which oxygen isreleased by heating may be oxygen-excess silicon oxide (SiO_(X) (X>2)).In the oxygen-excess silicon oxide (SiO_(X) (X>2)), the number of oxygenatoms per unit volume is more than twice the number of silicon atoms perunit volume. The number of silicon atoms and the number of oxygen atomsper unit volume are measured by Rutherford backscattering spectrometry.

In the above structure, as the insulating layer from which oxygen isreleased by heating, silicon oxide, silicon oxynitride, or aluminumoxide may be used. In addition, as the insulating layer which releases asmaller amount of oxygen than the first region, silicon oxide, siliconnitride, silicon nitride oxide, silicon oxynitride, aluminum oxide,aluminum nitride, or aluminum oxynitride may be used. The first regionmay be formed using a material having different constituent elementsfrom the material of the second region. For example, silicon oxide isused for the insulating layer from which oxygen is released by heating,whereas silicon nitride, silicon nitride oxide, silicon oxynitride,aluminum oxide, aluminum nitride, or aluminum oxynitride may be used forthe insulating layer which releases a smaller amount of oxygen than thefirst region. For example, in the case where silicon oxide is used forthe first region, aluminum oxide, whose oxygen diffusion coefficient isless than that of silicon oxide at an arbitrary temperature, ispreferably used for the second region. The second region whose oxygendiffusion coefficient is less than that of the first region is provided,whereby the amount of oxygen released from the first region and diffusedinto the second region can be reduced.

In this specification, silicon oxynitride refers to a substance thatcontains more oxygen than nitrogen. For example, silicon oxynitrideincludes oxygen, nitrogen, silicon, and hydrogen at concentrations ofgreater than or equal to 50 at. % and less than or equal to 70 at. %,greater than or equal to 0.5 at. % and less than or equal to 15 at. %,greater than or equal to 25 at. % and less than or equal to 35 at. %,and greater than or equal to 0 at. % and less than or equal to 10 at. %,respectively. In addition, silicon nitride oxide refers to a substancethat contains more nitrogen than oxygen. For example, silicon nitrideoxide contains oxygen, nitrogen, silicon, and hydrogen at concentrationsof greater than or equal to 5 at. % and less than or equal to 30 at. %,greater than or equal to 20 at. % and less than or equal to 55 at. %,greater than or equal to 25 at. % and less than or equal to 35 at. %,and greater than or equal to 10 at. % and less than or equal to 25 at.%, respectively. Note that percentages of the aforementioned elementsare obtained in the cases where measurement is performed usingRutherford backscattering spectrometry (RBS) or hydrogen forwardscattering (HFS). In addition, the total of the percentages of theconstituent elements does not exceed 100 at. %. Aluminum oxynitriderefers to a substance that contains more oxygen than nitrogen.

In the above structure, a surface of the first region and a surface ofthe second region are preferably aligned with each other. In otherwords, the first region preferably has the same thickness as the secondregion. In addition, at the vicinity of the boundary between the firstregion and the second region, the surface of the first region and thesurface of the second region are preferably formed continuously.

Alternatively, it is possible to omit the second region in the abovestructure. In that case, a first insulating layer may be selectivelyprovided over a substrate, and the first insulating layer may be used asthe insulating layer from which oxygen is released by heating.Alternatively, a second insulating layer may be provided over thesubstrate, the first insulating may be selectively provided over thesecond insulating layer, and the first insulating layer may be used asthe insulating layer from which oxygen is released by heating.

That is, one embodiment of the present invention is a semiconductordevice or a method for manufacturing the semiconductor device. Thesemiconductor device includes a first insulating layer selectivelyprovided over a substrate or a second insulating layer provided over thesubstrate; an oxide semiconductor layer which is provided in contactwith the first insulating, and the substrate or the second insulatinglayer and includes a channel region, a source region, and a drainregion; a gate insulating layer provided in contact with the oxidesemiconductor layer; and a gate electrode provided in contact with thegate insulating layer. The channel region of the oxide semiconductorlayer is provided in contact with the first insulating layer. The sourceregion and the drain region of the oxide semiconductor layer areprovided in contact with the substrate or the second insulating layer.The first insulating layer is an insulating layer from which oxygen isreleased by heating.

In the above structure, the insulating layer from which oxygen isreleased by heating may be oxygen-excess silicon oxide (SiO_(X) (X>2)).In the oxygen-excess silicon oxide (SiO_(X) (X>2)), the number of oxygenatoms per unit volume is more than twice the number of silicon atoms perunit volume. The number of silicon atoms and the number of oxygen atomsper unit volume are measured by Rutherford backscattering spectrometry.

In the above structure, as the insulating layer from which oxygen isreleased by heating, silicon oxide, silicon oxynitride, or aluminumoxide may be used.

In the above structure, the amount of oxygen released from the substrateor the second insulating layer is preferably smaller than that from thefirst insulating layer.

In the above structure, as the second insulating layer, silicon oxide,silicon nitride, silicon nitride oxide, silicon oxynitride, aluminumoxide, aluminum nitride, or aluminum oxynitride may be used.

In the above structure, an insulating layer from which oxygen isreleased by heating is preferably used as the gate insulating layer.Alternatively, silicon oxide in which the number of oxygen atoms is morethan twice the number of silicon atoms per unit volume is preferablyused as the gate insulating layer.

In the above structure, an interlayer insulating layer may be furtherprovided over the gate electrode, and a wiring which is in contact withthe oxide semiconductor layer through an opening portion provided in theinterlayer insulating layer may be further provided over the interlayerinsulating layer.

In the above structure, the source region and the drain region areobtained by reducing the resistance of the oxide semiconductor layer. Inother words, the source region and the drain region are formed byreducing the resistance of part of the oxide semiconductor layer. At thesame time, the channel region is formed in the oxide semiconductorlayer.

In the above structure, the insulating layer from which oxygen isreleased by heating is preferably formed by a sputtering method.Alternatively, the insulating layer from which oxygen is released byheating is preferably formed by a sputtering method using oxygen or amixed gas of oxygen and argon.

In the above structure, the oxide semiconductor layer is preferablyformed by a sputtering method.

In the above structure, after the oxide semiconductor layer is formed,heat treatment is preferably performed at a temperature higher than orequal to 100° C. and lower than or equal to 650° C.

In the above structure, the source region and the drain region may beformed by reducing the resistance of part of the oxide semiconductorlayer with the use of the gate electrode as a mask. In that case, thechannel region is formed in part of the oxide semiconductor layer whichis covered with the gate electrode.

In the above structure, the channel length L of the transistor can begreater than or equal to 10 nm and less than or equal to 10 μm, forexample, 0.1 μm to 0.5 μm. Needless to say, the channel length L may begreater than or equal to 10 μm. The channel width W can be greater thanor equal to 10 μm.

According to one embodiment of the present invention, an insulatinglayer from which oxygen is released by heating is provided as aninsulating layer in contact with a channel region of an oxidesemiconductor layer, and an insulating layer which releases a smalleramount of oxygen than the insulating layer in contact with the channelregion is provided as an insulating layer in contact with a sourceregion and a drain region of the oxide semiconductor layer. As a result,a transistor having a small off-state current, small variation in thethreshold voltage, a large on-state current, and stable electricalcharacteristics can be provided.

According to one embodiment of the present invention, a semiconductordevice including a highly reliable transistor having favorable electriccharacteristics is provided.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings:

FIGS. 1A and 1B are cross-sectional views each illustrating oneembodiment of a semiconductor device;

FIGS. 2A to 2D are cross-sectional views illustrating an example of amanufacturing process of a semiconductor device;

FIGS. 3A to 3D are cross-sectional views illustrating an example of amanufacturing process of a semiconductor device;

FIGS. 4A to 4D are cross-sectional views illustrating an example of amanufacturing process of a semiconductor device;

FIGS. 5A and 5B are cross-sectional views illustrating an example of amanufacturing process of a semiconductor device;

FIG. 6 is a cross-sectional view illustrating one embodiment of asemiconductor device;

FIGS. 7A to 7C each illustrate one embodiment of a semiconductor device;

FIGS. 8A to 8F each illustrate an electronic appliance as asemiconductor device; and

FIG. 9A to 9C are a top view and cross-sectional views illustrating oneembodiment of a semiconductor device.

DETAILED DESCRIPTION OF THE INVENTION

Hereinafter, embodiments of the present invention will be described indetail with reference to the accompanying drawings. However, the presentinvention is not limited to the description below and it is easilyunderstood by those skilled in the art that the mode and details can bechanged variously. Therefore, the present invention is not construed asbeing limited to description of the embodiments. In describingstructures of the present invention with reference to the drawings, thesame reference numerals are used in common for the same portions indifferent drawings. Note that the same hatch pattern is applied tosimilar parts, and the similar parts are not especially denoted byreference numerals in some cases.

Note that the ordinal numbers such as “first” and “second” in thisspecification are used for convenience and do not denote the order ofsteps or the stacking order of layers. In addition, the ordinal numbersin this specification do not denote particular names which specify thepresent invention.

Embodiment 1

In this embodiment, an embodiment of a semiconductor device and a methodfor manufacturing the semiconductor device will be described withreference to FIGS. 1A and 1B, FIGS. 2A to 2D, FIGS. 3A to 3D, FIGS. 4Ato 4D, and FIGS. 5A and 5B.

FIGS. 1A and 1B each illustrate a cross-sectional view of a coplanartransistor 155, which is one mode of a top-gate transistor, as anexample of a semiconductor device according to an embodiment of thepresent invention.

The transistor 155 illustrated in FIG. 1A includes an insulating layer103, an oxide semiconductor layer 106, a gate insulating layer 112, anda gate electrode 114, which are over a substrate 100. The insulatinglayer 103 includes a first region 101 and a second region 102. The oxidesemiconductor layer 106 of the transistor 155 includes a channel region126, a source region 122 a, and a drain region 122 b. The channel region126, the source region 122 a, and the drain region 122 b are included inthe same layer.

The oxide semiconductor layer 106 is provided in contact with the firstregion 101 and the second region 102. The channel region 126 of theoxide semiconductor layer 106 is provided in contact with the firstregion 101. The source region 122 a and the drain region 122 b of theoxide semiconductor layer 106 are provided in contact with the secondregion 102. The gate insulating layer 112 is provided in contact withthe oxide semiconductor layer 106. The gate electrode 114 is provided incontact with the gate insulating layer 112. An interlayer insulatinglayer 124 is provided over the gate electrode 114. The source region 122a and the drain region 122 b are electrically connected to a wiring 108a and a wiring 108 b, respectively, through the interlayer insulatinglayer 124. The wiring 108 a and the wiring 108 b function as a sourceelectrode and a drain electrode. Note that the width of the gateinsulating layer 112 is the same as that of the gate electrode 114 inFIG. 1A; however, an embodiment of the present invention is not limitedthereto. Instead of the gate insulating layer 112, a gate insulatinglayer 113 may be provided over the insulating layer 103 and the oxidesemiconductor layer 106 as illustrated in FIG. 1B. Note that the gateinsulating layer 113 may be formed using the same method and the samematerial as those of the gate insulating layer 112. The gate insulatinglayer 113 can be substituted for the gate insulating layer 112 in thisspecification as appropriate.

As the material of the first region 101, silicon oxide, siliconoxynitride, aluminum oxide, a mixed material of any of them, or the likemay be used. Oxygen is released from the first region 101 by heating. Torelease oxygen by heating means that the released amount of oxygen whichis converted to oxygen atoms is greater than or equal to 1×10¹⁸atoms/cm³, preferably greater than or equal to 3×10²⁰ atoms/cm³ inthermal desorption spectroscopy (TDS). Alternatively, as the material ofthe first region 101, oxygen-excess silicon oxide (SiO_(X) (X>2)) may beused. In the oxygen-excess silicon oxide (SiO_(X) (X>2)), the number ofoxygen atoms per unit volume is more than twice the number of siliconatoms per unit volume. The number of silicon atoms and the number ofoxygen atoms per unit volume are measured by Rutherford backscatteringspectrometry.

As the material of the second region 102, silicon oxide, siliconnitride, silicon nitride oxide, silicon oxynitride, aluminum oxide,aluminum nitride, or aluminum oxynitride may be used. The second region102 is an insulating layer which releases a smaller amount of oxygenthan the first region 101. Note that the first region 101 may be formedusing a material having constituent elements which are the same as ordifferent from those of the material of the second region 102 or amaterial whose two or more constituent elements are the same as those ofthe material of the second region 102. In the case where the firstregion 101 is formed using the material having the same constituentelements as the material of the second region 102 or the a materialwhose two or more constituent elements are the same as those of thematerial of the second region 102, a material whose number of oxygenatoms per unit volume is smaller than that per unit volume of the firstregion 101 may be used as the material of the second region 102. Forexample, silicon oxide (SiO_(X) (X>2)) in which the number of oxygenatoms is more than twice the number of silicon atoms per unit volume maybe used as the material of the first region 101, whereas silicon oxide(SiO_(X) (X≦2)) whose number of oxygen atoms per unit volume is smallerthan the number of oxygen atoms per unit volume of the first region 101may be used as the material of the second region 102. Alternatively,silicon oxynitride whose number of oxygen atoms per unit volume issmaller than the number of oxygen atoms per unit volume of the firstregion 101 may be used as the material of the second region 102. Furtheralternatively, an organic insulating material which can be formed by wetprocess, such as an acrylic resin, polyimide, a benzocyclobutene resin,polyamide, or an epoxy resin, may be used as the material of the secondregion 102. Other than such organic insulating materials, an inorganicinsulating material which can be formed by wet process, such as alow-dielectric constant material (a low-k material), a siloxane-basedresin, phosphosilicate glass (PSG), or borophosphosilicate glass (BPSG),may be used. At a predetermined temperature (e.g., any of temperaturesin the range of 100° C. to 650° C.), the oxygen diffusion coefficient ofthe second region 102 is preferably lower than that of the first region101. Thus, the amount of oxygen which is released from the first region101 and diffused into the second region 102 can be reduced.

The insulating layer 103 including the first region 101 and the secondregion 102 may be formed by stacking the above material and siliconoxide, silicon nitride, silicon oxynitride, silicon nitride oxide,aluminum oxide, aluminum nitride, aluminum oxynitride, a mixed materialthereof, or the like. In the case where the insulating layer 103 isformed with a stacked structure, a layer in contact with the oxidesemiconductor layer 106 is preferably formed using the material of thefirst region 101 and the material of the second region 102. Note thatthe insulating layer 103 functions as a base layer of the transistor155.

As a material used for the oxide semiconductor layer 106, anIn—Sn—Ga—Zn—O-based material, which is a four-component metal oxide; anIn—Ga—Zn—O-based material, an In—Sn—Zn—O-based material, anIn—Al—Zn—O-based material, a Sn—Ga—Zn—O-based material, anAl—Ga—Zn—O-based material, or a Sn—Al—Zn—O-based material, which arethree-component metal oxides; an In—Zn—O-based material, a Sn—Zn—O-basedmaterial, an Al—Zn—O-based material, a Zn—Mg—O-based material, aSn—Mg—O-based material, an In—Mg—O-based material, or an In—Ga—O-basedmaterial, which are two-component metal oxides; an In—O—based material;a Sn—O-based material; a Zn—O-based material; or the like can be used.In addition, any of the above materials may contain silicon oxide. Here,for example, an In—Ga—Zn—O-based material means an oxide layercontaining indium (In), gallium (Ga), and zinc (Zn), and there is noparticular limitation on the composition ratio. Further, theIn—Ga—Zn—O-based oxide semiconductor may contain an element other thanIn, Ga, and Zn.

In the case where an In—Zn—O-based material is used as the oxidesemiconductor layer 106, the atomic ratio is set so that In/Zn is ingreater than or equal to 0.5 and less than or equal to 50, preferablygreater than or equal to 1 and less than or equal to 20, more preferablygreater than or equal to 1.5 and less than or equal to 15. When theatomic ratio of Zn is in the above range, the field effect mobility ofthe transistor can be improved. Here, when the atomic ratio of thecompound is In:Zn:O=X:Y:Z, it is preferable to satisfy the relation ofZ>1.5X+Y.

Alternatively, the oxide semiconductor layer 106 can be formed using athin film formed using a material represented by the chemical formula,InMO₃(ZnO)_(m) (m>0). Here, M represents one or more metal elementsselected from Ga, Al, Mn, and Co. For example, M can be Ga, Ga and Al,Ga and Mn, Ga and Co, or the like.

The channel region 126 and the first region 101 are in contact with eachother, whereby the interface state density between the first region 101and the channel region 126 and oxygen deficiency in the channel region126 can be reduced. As a result, charge or the like which can begenerated due to the operation of the semiconductor device or the likecan be sufficiently prevented from being trapped at the interfacebetween the first region 101 and the channel region 126.

Further, charge is generated due to oxygen deficiency of the channelregion 126 in some cases. In general, part of oxygen deficiency in achannel region serves as a donor and generates electrons that arecarriers. As a result, the threshold voltage of the transistor shifts inthe negative direction. A sufficient amount of oxygen is released to thechannel region 126 from the first region 101 that is an insulating layerin contact with the channel region 126, whereby the oxygen deficiency inthe channel region 126, which causes the shift of the threshold voltagein the negative direction, can be compensated.

In other words, when oxygen deficiency is caused in the channel region126, it is difficult to suppress charge trapping at the interfacebetween the channel region 126 and the first region 101 that is aninsulating layer in contact with the channel region 126. However, byproviding an insulating layer from which oxygen is released by heatingas the first region 101, the interface state density between the channelregion 126 and the first region 101 and the oxygen deficiency in thechannel region 126 can be reduced, and influence by the charge trappingat the interface between the channel region 126 and the first region 101can be reduced.

In addition, the source region 122 a and the drain region 122 b areprovided in contact with the second region 102 which releases a smalleramount of oxygen than the first region 101, so that oxygen is notsupplied to the source region 122 a and the drain region 122 b. This isbased on the fact that part of the oxygen deficiency in the oxidesemiconductor layer generates electrons that are carriers. In otherwords, this is based on a technical idea that is to suppress theincrease of the resistance of the source region 122 a and the drainregion 122 b which is caused by the reduction of oxygen deficiency bysupply of oxygen. For example, an insulating layer which releases oxygenof less than 1×10¹⁸ atoms/cm³ in TDS analysis can be used as the secondregion 102 in contact with the source region 122 a and the drain region122 b.

Owing to an effect of suppressing the charge trapping at the interfaceof the channel region 126 of the oxide semiconductor layer andsuppressing the increase of the resistance of the source region 122 aand the drain region 122 b, it is possible to suppress a malfunctionsuch as the reduction of an on-state current of the transistor 155, towhich the reduction of current flowing through the source region 122 aand the drain region 122 b which is caused by increasing the resistanceof the source region 122 a and the drain region 122 b is attributed. Inaddition, a malfunction such as the increase of an off-state current ofthe transistor 155 including the oxide semiconductor and the shift ofthe threshold voltage can be suppressed. Further, the reliability of thesemiconductor device can be improved.

The gate insulating layer 112 may include a structure (e.g., a material)similar to that of the first region 101. In other words, the gateinsulating layer 112 may be an insulating layer from which oxygen isreleased by heating. Alternatively, a material having a high dielectricconstant, such as hafnium oxide or aluminum oxide, may be used for thegate insulating layer 112 considering the function of the gateinsulating layer of the transistor. In addition, considering a gatewithstand voltage or the interface state with the oxide semiconductor, amaterial having a high dielectric constant, such as hafnium oxide oraluminum oxide, may be stacked on silicon oxide, silicon oxynitride, orsilicon nitride.

The gate electrode 114 can be formed using a metal material such asmolybdenum, titanium, tantalum, tungsten, aluminum, copper, neodymium,or scandium, nitride of any of these metal materials, or an alloymaterial which contains any of these metal materials as its maincomponent. Note that the gate electrode 114 may have a single-layerstructure or a stacked structure.

Further, the interlayer insulating layer 124 may be provided over thetransistor 155. The interlayer insulating layer 124 may include astructure (e.g., a material) similar to that of the second region 102.In addition, an opening portion may be formed in the interlayerinsulating layer 124 in order to obtain electrical connection of thewiring 108 a and the wiring 108 b with the source region 122 a and thedrain region 122 b.

As the conductive layer used for the wiring 108 a and the wiring 108 b,for example, a metal layer containing an element selected from Al, Cr,Cu, Ta, Ti, Mo, and W, or a metal nitride layer containing any of theabove elements as its component (e.g., a titanium nitride layer, amolybdenum nitride layer, or a tungsten nitride layer) can be used. Ahigh-melting-point metal layer of Ti, Mo, W, or the like or a metalnitride layer of any of these elements (a titanium nitride layer, amolybdenum nitride layer, or a tungsten nitride layer) may be stacked onone of or both a bottom side and a top side of a metal layer of Al, Cu,or the like.

In the transistor 155, a second gate electrode may further be providedbelow the oxide semiconductor layer 106. Note that it is not alwaysnecessary but preferable to process the oxide semiconductor layer 106into an island shape.

Examples of a manufacturing process of the transistor 155 in FIG. 1Awill be described below with reference to FIGS. 2A to 2D, FIGS. 3A to3D, FIGS. 4A to 4D, and FIGS. 5A and 5B.

First, an example of a manufacturing process of the transistor 155illustrated in FIG. 1A will be described with reference to FIGS. 2A to2D and FIGS. 3A to 3D.

A first insulating layer 131 is formed over the substrate 100 (see FIG.2A), and the first insulating layer 131 is processed by a method such asphotolithography to form the island-shaped first region 101 (see FIG.2B). A photomask used in the formation of the first region 101 can bethe same as a photomask used in the formation of the gate electrode.Oxygen is released from the first region 101 by heating. As the materialof the first region 101, oxygen-excess silicon oxide (SiO_(X) (X>2)) maybe used.

There is no particular limitation on the property of a material and thelike of the substrate 100 as long as the material has heat resistanceenough to withstand at least heat treatment to be performed later. Forexample, a glass substrate, a ceramic substrate, a quartz substrate, ora sapphire substrate can be used as the substrate 100. Alternatively, asingle crystal semiconductor substrate or a polycrystallinesemiconductor substrate made of silicon, silicon carbide, or the like, acompound semiconductor substrate made of silicon germanium or the like,an SOI substrate, or the like may be used as the substrate 100. Stillalternatively, any of these substrates further provided with asemiconductor element may be used as the substrate 100.

A flexible substrate may alternatively be used as the substrate 100. Inthe case where a transistor is provided over the flexible substrate, thetransistor may be directly formed on the flexible substrate.Alternatively, the transistor may be formed over a different substrateand then separated to be transferred to the flexible substrate that isthe substrate 100. Note that in order to separate the transistor fromthe substrate and transfer it to the flexible substrate, a separationlayer is preferably formed between the different substrate and thetransistor.

As a formation method of the first insulating layer 131 which is to bethe first region 101, a plasma CVD method or a sputtering method can beemployed, for example. The insulating layer from which oxygen isreleased by heating is preferably formed by a sputtering method.

In order to form the insulating layer from which oxygen is released byheating by a sputtering method, in the case where oxygen or a mixed gasof oxygen and a rare gas (e.g., argon) is used as a deposition gas, theproportion of oxygen is preferably set higher. For example, theconcentration of oxygen in the whole gas is preferably set to be higherthan or equal to 6% and lower than 100%.

As the material of the first insulating layer 131 which is to be thefirst region 101, silicon oxide, silicon oxynitride, aluminum oxide, amixed material of any of them, or the like may be used.

For example, as the first insulating layer 131, silicon oxide is formedby an RF sputtering method in the following conditions: quartz(preferably synthesized quartz) is used as a target; a substratetemperature is higher than or equal to 30° C. and lower than or equal to450° C. (preferably higher than or equal to 70° C. and lower than orequal to 200° C.); oxygen or oxygen and argon are used as a depositiongas; and a proportion of O₂/(O₂+Ar) in the deposition gas is greaterthan or equal to 1% and less than or equal to 100% (preferably greaterthan or equal to 6% and less than or equal to 100%).

The thickness of each of the first insulating layer 131 and the firstregion 101 is preferably greater than or equal to 50 nm and morepreferably greater than or equal to 200 nm. The first insulating layer131 and the first region 101 have large thicknesses, so that the amountof oxygen released from the first region 101 can be increased.

Next, a second insulating layer 132 is formed over the substrate 100 andthe first region 101 (see FIG. 2C). After that, the second insulatinglayer 132 is processed until a surface of the first region 101 isexposed, so that the insulating layer 103 in which the second region 102is in contact with the first region 101 is formed (see FIG. 2D). Thesecond region 102 is an insulating layer which releases a smaller amountof oxygen than the first region 101. Note that in processing of thesecond insulating layer 132, a surface of the first region 101 may beprocessed at the same time so that part of the first region 101 isremoved.

As a formation method for the second insulating layer 132, for example,a plasma CVD method, a sputtering method, or the like can be used.

As the material of the second insulating layer 132, silicon oxide,silicon nitride, silicon nitride oxide, silicon oxynitride, aluminumoxide, aluminum nitride, or aluminum oxynitride may be used.

For example, a silicon nitride film is formed by a plasma CVD method asthe second insulating layer 132. Alternatively, as the second insulatinglayer 132, silicon oxide may be formed by a plasma CVD method.

After the above process, the surface of the first region 101 and thesurface of the second region 102 are preferably aligned with each other.For example, the second insulating layer 132 is subjected to polishingtreatment such as chemical mechanical polishing (CMP) or etchingtreatment until the surface of the first region 101 is exposed, so thatthe insulating layer 103, in which the second region 102 is in contactwith the first region 101 and the surface of the first region 101 andthe surface of the second region 102 are aligned with each other, can beformed. The alignment of the surface of the first region 101 and thesurface of the second region 102 can lead to prevention of disconnectionof the oxide semiconductor layer to be formed thereover. This effect isenhanced when the oxide semiconductor layer is thin. Prevention of thedisconnection of the oxide semiconductor layer can lead to prevention ofdisconnection of the source region and the drain region, therebysuppressing reduction of the on-state current. In addition,disconnection of the gate insulating layer to be formed over the oxidesemiconductor layer can be prevented. Prevention of the disconnection ofthe gate insulating layer can suppress the increase of leakage currentand the reduction of a dielectric strength voltage.

Note that the thickness of the second region 102, that is, the thicknessof the insulating layer 103 is the same as that of the first insulatinglayer 131 and that of the first region 101. Specifically, the thicknessof the second region 102, that is, the thickness of the insulating layer103 is preferably greater than or equal to 50 nm, more preferablygreater than or equal to 200 nm. Note that the thickness of the firstinsulating layer 131 subjected to the polishing treatment or etchingtreatment may be smaller than that of the just-formed first insulatinglayer 131.

Alternatively, the insulating layer 103 including the first region 101and the second region 102 may be formed by stacking the above materialand silicon oxide, silicon nitride, silicon oxynitride, silicon nitrideoxide, aluminum oxide, aluminum nitride, aluminum oxynitride, a mixedmaterial thereof, or the like. In the case where the insulating layer103 is formed with a stacked structure, a layer in contact with theoxide semiconductor layer 106 is preferably formed using the material ofthe first region 101 and the material of the second region 102. Notethat the insulating layer 103 functions as a base layer of thetransistor 155.

Note that the first region 101 is formed and then the second region 102is formed here; however, the formation order of the first region 101 andthe second region 102 may be inverted, that is, the second region 102may be formed and then the first region 101 may be formed. In that case,after the second region 102 is selectively formed, the first insulatinglayer 131 is formed over the entire surface, and the first insulatinglayer 131 is subjected to polishing treatment or etching treatment untilthe surface of the second region 102 is exposed, so that the insulatinglayer 103 in which the second region 102 is in contact with the firstregion 101 can be formed.

Next, an oxide semiconductor layer is formed over the insulating layer103 and processed to form the island-shaped oxide semiconductor layer106 (see FIG. 3A). The oxide semiconductor layer 106 is formed to be incontact with the first region 101 and the second region 102.

For example, the oxide semiconductor layer 106 can be formed by asputtering method, a vacuum evaporation method, a pulse laser depositionmethod, a CVD method, or the like. The thickness of the oxidesemiconductor layer 106 is preferably greater than or equal to 3 nm andless than or equal to 50 nm. This is because when the oxidesemiconductor layer 106 is too thick (e.g., 100 nm or more), there is apossibility that the short channel effect has a large influence and thetransistor with a small size is normally on. Here, “normally on” means astate where a channel exists without application of a voltage to a gateelectrode and a current flows through the transistor.

In this embodiment, the oxide semiconductor layer 106 is formed by asputtering method with the use of an In—Ga—Zn—O-based oxide target.

As the In—Ga—Zn—O-based oxide target, for example, an oxide targethaving a composition ratio of In₂O₃:Ga₂O₃:ZnO=1:1:1 [molar ratio] can beused. Note that it is not necessary to limit the material and thecomposition ratio of the target to the above. For example, an oxidetarget having a composition ratio of In₂O₃:Ga₂O₃:ZnO=1:1:2 [molar ratio]can be used.

The relative density of the oxide target is higher than or equal to 90%and lower than or equal to 100%, preferably higher than or equal to 95%to lower than or equal 100%. This is because, with the use of the metaloxide target with a high relative density, the dense oxide semiconductorlayer can be formed.

The deposition atmosphere may be a rare gas (typically argon)atmosphere, an oxygen atmosphere, a mixed atmosphere containing a raregas and oxygen, or the like. Moreover, it is preferably performed underan atmosphere using a high-purity gas in which impurities such ashydrogen, water, a hydroxyl group, and hydride are sufficiently removedso that entry of hydrogen, water, a hydroxyl group, and hydride into theoxide semiconductor layer can be prevented.

For example, the oxide semiconductor layer 106 can be formed as follows.

An example of the deposition conditions is as follows: the distancebetween the substrate and the target is 60 mm; the pressure is 0.4 Pa;the direct-current (DC) power is 0.5 kW; and the deposition atmosphereis a mixed atmosphere containing argon and oxygen (the flow rate of theoxygen is 33%). Note that a pulse DC sputtering method is preferablebecause powder substances (also referred to as particles or dust)generated in deposition can be reduced and the film thickness can beuniform.

At this time, the substrate temperature is set to higher than or equalto 100° C. and lower than or equal to 450° C., preferably higher than orequal to 150° C. and lower than or equal to 250° C., whereby oxygen isreleased from the first region 101, so that oxygen deficiency of aportion of the oxide semiconductor layer 106 in contact with the firstregion 101 (a portion to be the channel region 126) can be reduced, andthe interface state density between the oxide semiconductor layer 106and the first region 101 can be reduced.

When portions of the oxide semiconductor layer 106 which are not incontact with the first region 101 (portions to be the source region 122a and the drain region 122 b) are in contact with the second region 102which releases a smaller amount of oxygen than the first region 101, theincrease of the resistance of the portions of the oxide semiconductorlayer 106 can be suppressed.

Note that before the oxide semiconductor layer 106 is formed by asputtering method, a substance attached to a surface where the oxidesemiconductor layer 106 is to be formed (e.g., a surface of theinsulating layer 103) may be removed by reverse sputtering in which anargon gas is introduced and plasma is generated. Here, the reversesputtering is a method by which ions collide with a surface to beprocessed so that the surface is modified, in contrast to normalsputtering by which ions collide with a sputtering target. An example ofa method for making ions collide with a surface to be processed is amethod in which high-frequency voltage is applied to the surface side ina rare atmosphere so that plasma is generated near the object to beprocessed. Note that, instead of a rare gas atmosphere, an atmosphere ofnitrogen, oxygen, or the like may be used.

The oxide semiconductor layer 106 can be processed by etching after amask having a desired shape is formed over the oxide semiconductorlayer. The mask may be formed by a method such as photolithography or anink-jet method. Alternatively, the mask may be formed by an ink-jetmethod or the like.

For the etching of the oxide semiconductor layer, either wet etching ordry etching may be employed. Needless to say, both of them may beemployed in combination.

After that, heat treatment (first heat treatment) is preferablyperformed on the oxide semiconductor layer 106. By the first heattreatment, excessive hydrogen (including water and a hydroxyl group) inthe oxide semiconductor layer 106 can be removed. The temperature of thefirst heat treatment is higher than or equal to 100° C. and lower thanor equal to 650° C. or lower than the strain point of the substrate,preferably higher than or equal to 250° C. and lower than or equal to600° C. The atmosphere of the first heat treatment is an oxidation gasatmosphere or an inert gas atmosphere.

Note that the inert gas contains nitrogen or a rare gas (e.g., helium,neon, or argon) as its main component and preferably does not containwater, hydrogen, or the like. For example, the purity of nitrogen or arare gas such as helium, neon, or argon introduced into a heat treatmentapparatus is set to 6N (99.9999%) or higher, preferably 7N (99.99999%)or higher (i.e., the impurity concentration is 1 ppm or lower,preferably 0.1 ppm or lower). The inert gas atmosphere is an atmospherethat contains an inert gas as its main component and contains a reactivegas at a concentration less than 10 ppm.

Note that the oxidation gas is oxygen, ozone, nitrogen dioxide, or thelike, and it is preferable that the oxidation gas does not containwater, hydrogen, and the like. For example, the purity of oxygen, ozone,or nitrogen dioxide introduced into a heat treatment apparatus is set to6N (99.9999%) or higher, preferably 7N (99.99999%) or higher (i.e., theimpurity concentration is 1 ppm or lower, preferably 0.1 ppm or lower).As the oxidation gas atmosphere, an atmosphere in which an oxidation gasis mixed with an inert gas may be used, and the oxidation gas of atleast 10 ppm is contained.

By the first heat treatment, oxygen is released from the first region101, so that the interface state density between the first region 101and the portion of the oxide semiconductor layer 106 which is in contactwith the first region 101 (the portion to be the channel region 126) canbe reduced, and the oxygen deficiency in the portion of the oxidesemiconductor layer 106 which is in contact with the first region 101can be reduced. By the above reduction of the interface state density,the fluctuation in the threshold voltage after a BT test can be reduced.Further, in general, it is known that part of the oxygen deficiency inan oxide semiconductor layer serves as a donor and generates electronsthat are carriers. By the generation of electrons in the oxidesemiconductor layer 106, the threshold voltage of the transistor 155shifts in the negative direction, so that the transistor 155 tends to benormally on. The oxygen deficiency in the oxide semiconductor layer 106is compensated, whereby the amount of the shift of the threshold voltagein the negative direction can be reduced.

In addition, the portions of the oxide semiconductor layer 106 which arenot in contact with the first region 101 (the portions to be the sourceregion 122 a and the drain region 122 b) are in contact with the secondregion 102 which releases a smaller amount of oxygen than the firstregion 101, whereby the increase of the resistance of the portions ofthe oxide semiconductor layer 106 can be suppressed.

The heat treatment can be performed in such a manner that, for example,an object is introduced into an electric furnace in which a resistanceheating element or the like is used and heated at 350° C. in a nitrogenatmosphere for an hour. During the heat treatment, the oxidesemiconductor layer is not exposed to the air to prevent the entry ofwater and hydrogen.

Note that the heat treatment apparatus is not limited to an electricfurnace, and may include a device for heating an object by heatconduction or heat radiation from a medium such as a heated gas. Forexample, an RTA (rapid thermal anneal) apparatus such as a GRTA (gasrapid thermal anneal) apparatus or an LRTA (lamp rapid thermal anneal)apparatus can be used. An LRTA apparatus is an apparatus for heating anobject to be processed by radiation of light (an electromagnetic wave)emitted from a lamp such as a halogen lamp, a metal halide lamp, a xenonarc lamp, a carbon arc lamp, a high pressure sodium lamp, or a highpressure mercury lamp. A GRTA apparatus is an apparatus for performingheat treatment using a high-temperature gas. As the high temperaturegas, used is an inert gas which does not react with an object to beprocessed in heat treatment, for example, nitrogen or a rare gas such asargon.

For example, as the first heat treatment, a GRTA process may beperformed as follows. The object is put in an inert gas atmosphere thathas been heated, heated for several minutes, and taken out from theinert gas atmosphere. The GRTA process enables high-temperature heattreatment for a short time. Moreover, the GRTA process can be employedeven when the temperature exceeds the upper temperature limit of theobject. Note that the inert gas atmosphere may be switched to anatmosphere containing an oxidation gas during the treatment. This isbecause by performing the first heat treatment in an atmospherecontaining the oxidation gas, oxygen deficiency in the oxidesemiconductor layer 106 can be compensated and defect levels in anenergy gap due to the oxygen deficiency can be reduced.

The above heat treatment (first heat treatment) can be referred to asdehydration treatment, dehydrogenation treatment, or the like because ofits advantageous effect of removing hydrogen, water, and the like. Inaddition, the above heat treatment can also be referred to as treatmentfor supplying oxygen because of its advantageous effect of supplyingoxygen from the insulating layer, a heat treatment atmosphere, or thelike. The dehydration treatment, dehydrogenation treatment, or treatmentfor supplying oxygen may be performed at the timing, for example, afterthe oxide semiconductor layer is processed to have an island shape. Suchdehydration treatment, dehydrogenation treatment, or treatment forsupplying oxygen may be performed once or plural times.

Note that the case is described here where the first heat treatment isperformed after the oxide semiconductor layer 106 is processed to havean island shape; however, one embodiment of the present invention is notlimited thereto. The oxide semiconductor layer 106 may be processedafter the first heat treatment.

Next, an insulating layer is formed to be in contact with the oxidesemiconductor layer 106, and a conductive layer is formed to be incontact with the insulating layer. The insulating layer and theconductive layer are processed to the same pattern by photolithographyto form the gate insulating layer 112 and the gate electrode 114 (seeFIG. 3B). In other words, the gate electrode 114 and the gate insulatinglayer 112 can be formed using the same mask. Alternatively, the gateelectrode 114 may be formed and then, the gate insulating layer 112 maybe formed using the gate electrode 114 as a mask.

The gate insulating layer 112 may includes a structure (e.g., amaterial) similar to that of the first region 101. Alternatively, amaterial having a high dielectric constant, such as hafnium oxide oraluminum oxide, may be used for the gate insulating layer 112considering the function of the gate insulating layer of the transistor.In addition, considering a gate withstand voltage or the interface statewith the oxide semiconductor, a material having a high dielectricconstant, such as hafnium oxide or aluminum oxide, may be stacked onsilicon oxide, silicon oxynitride, or silicon nitride. The totalthickness of the gate insulating layer 112 is preferably greater than orequal to 1 nm and less than or equal to 300 nm, more preferably greaterthan or equal to 5 nm and less than or equal to 50 nm. As the thicknessof the gate insulating layer is larger, a short channel effect isenhanced more and the threshold voltage tends to shift more in thenegative side. In addition, it is found that when the thickness of thegate insulating layer is less than or equal to 5 nm, leakage due to atunnel current is increased.

Second heat treatment is preferably performed after the gate insulatinglayer 112 is formed. The temperature of the second heat treatment ishigher than or equal to 100° C. and lower than or equal to 650° C. orlower than the strain point of the substrate, preferably higher than orequal to 250° C. and lower than or equal to 600° C. or lower than thestrain point of the substrate.

The second heat treatment may be performed under an atmosphere of anoxidation gas or an inert gas. It is preferable that the atmosphere ofan oxidation gas or an inert gas do not contain water, hydrogen, and thelike. Further, the purity of the gas introduced into a heat treatmentapparatus is preferably set to 6N (99.9999%) or higher, more preferably7N (99.99999%) or higher (that is, the impurity concentration is 1 ppmor lower, preferably 0.1 ppm or lower).

The second heat treatment is performed while the oxide semiconductorlayer 106 is in contact with the first region 101 and the gateinsulating layer 112. Thus, oxygen, which is one of main components ofthe oxide semiconductor, can be supplied from the first region 101 andthe gate insulating layer 112 which contain oxygen, to the oxidesemiconductor layer 106. Accordingly, oxygen deficiency in the oxidesemiconductor layer 106, the interface state density between the firstregion 101 and the oxide semiconductor layer 106, and the interfacestate density between the oxide semiconductor layer and the gateinsulating layer 112 can be reduced. At the same time, deficiency in thegate insulating layer 112 can also be reduced.

Note that there is no particular limitation on the timing of the secondheat treatment as long as it is after the gate insulating layer 112 isformed. The second heat treatment may be performed plural times.

The gate electrode 114 can be formed using a metal material such asmolybdenum, titanium, tantalum, tungsten, aluminum, copper, neodymium,or scandium, nitride of any of these metal materials, or an alloymaterial which contains any of these metal materials as its maincomponent. Note that the gate electrode 114 may have a single-layerstructure or a stacked structure.

Next, the resistance of the oxide semiconductor layer 106 is reducedusing the gate electrode 114 as a mask, so that the source region 122 aand the drain region 122 b are formed. A region under the gate electrode114 where the resistance is not reduced becomes the channel region 126(see FIG. 3C). As a method for reducing the resistance, argon plasmatreatment, hydrogen plasma treatment, ammonia plasma treatment, and thelike can be given. At this time, the channel length L of the transistoris determined by the width of the gate electrode 114. By patterningusing the gate electrode 114 as the mask in this manner, the sourceregion 122 a and the drain region 122 b do not overlap with the gateelectrode 114 and parasitic capacitance in the region is not generated;therefore, the operation speed of the transistor can be increased.

Next, the interlayer insulating layer 124 is formed and an openingportion is provided in a region of the interlayer insulating layer 124which overlaps with the source region 122 a and the drain region 122 b.Then, a conductive layer is formed and processed to form the wiring 108a and the wiring 108 b (see FIG. 3D).

As the conductive layer used for the wiring 108 a and the wiring 108 b,for example, a metal layer containing an element selected from Al, Cr,Cu, Ta, Ti, Mo, and W, or a metal nitride layer containing any of theabove elements as its component (e.g., a titanium nitride layer, amolybdenum nitride layer, or a tungsten nitride layer) can be used. Ahigh-melting-point metal layer of Ti, Mo, W, or the like or a metalnitride layer of any of these elements (a titanium nitride layer, amolybdenum nitride layer, or a tungsten nitride layer) may be stacked onone of or both a bottom side and a top side of a metal layer of Al, Cu,or the like.

Alternatively, the conductive layer used for the wiring 108 a and thewiring 108 b may be formed using a conductive metal oxide. As theconductive metal oxide, indium oxide (In₂O₃ or the like), tin oxide(SnO₂ or the like), zinc oxide (ZnO or the like), indium oxide-tin oxidealloy (In₂O₃—SnO₂ or the like, which is abbreviated to ITO), indiumoxide-zinc oxide alloy (In₂O₃—ZnO or the like), or any of these metaloxide materials in which silicon oxide is contained can be used.

The conductive layer can be processed by etching with the use of aresist mask. Ultraviolet, a KrF laser light, an ArF laser light, or thelike is preferably used for light exposure for forming a resist mask forthe etching.

Through the above process, the transistor 155 is formed.

Next, an example of a manufacturing process of the insulating layer 103is described with reference to FIGS. 4A to 4D. First, through the sameprocess as FIGS. 2A to 2C, the first region 101 is formed over thesubstrate 100, and the second insulating layer 132 is formed over thesubstrate 100 and the first region 101 (see FIG. 4A). Then, a thirdinsulating layer 133 is formed over the second insulating layer 132 (seeFIG. 4B). As the third insulating layer 133, a planarization insulatinglayer can be used. For example, as a material of the third insulatinglayer 133, an organic insulating material which can be formed by wetprocess, such as an acrylic resin, polyimide, a benzocyclobutene resin,polyamide, or an epoxy resin can be used. Other than such organicinsulating materials, it is possible to use an inorganic insulatingmaterial which can be formed by wet process, such as a low-dielectricconstant material (a low-k material), a siloxane-based resin,phosphosilicate glass (PSG), or borophosphosilicate glass (BPSG).

The third insulating layer 133 can be formed, depending on the material,by a spin coating method, a dipping method, spray coating, a dropletdischarge method (e.g., an inkjet method, screen printing, or offsetprinting), roll coating, curtain coating, knife coating, or the like.

Then, the third insulating layer 133 and the second insulating layer 132are subjected to etching treatment. An etchant whose etching selectionratio of the third insulating layer 133 and the second insulating layer132 is 1:1 or close to 1:1 is used for the etching treatment.Accordingly, an etching rate of the third insulating layer 133 can besubstantially the same as an etching rate of the second insulating layer132 (see FIG. 4C). Note that the third insulating layer 133 and thesecond insulating layer 132 may be etched by either dry etching or wetetching.

Then, the third insulating layer 133 and the second insulating layer 132are subjected to the etching treatment until the surface of the firstregion 101 is exposed, so that the insulating layer 103, in which thesecond region 102 is in contact with the first region 101, and thesurface of the first region 101 and the surface of the second region 102are aligned with each other can be formed (see FIG. 4D). The alignmentof the surface of the first region 101 and the surface of the secondregion 102 can lead to prevention of disconnection of the oxidesemiconductor layer to be formed thereover. This effect is enhanced whenthe oxide semiconductor layer 106 is thin. Prevention of thedisconnection of the oxide semiconductor layer 106 can preventdisconnection of the source region 122 a and the drain region 122 b andcan suppress the reduction of the on-state current. In addition,disconnection of the gate insulating layer 112 to be formed over theoxide semiconductor layer 106 can be prevented. Prevention of thedisconnection of the gate insulating layer 112 can suppress the increaseof leakage current and the reduction of a dielectric strength voltage.

Note that the first region 101 is formed and then the second region 102is formed here; however, the formation order of the first region 101 andthe second region 102 may be inverted, that is, the second region 102may be formed and then the first region 101 may be formed. In that case,after the second region 102 is selectively formed, the first insulatinglayer 131 is formed over the entire surface, and the third insulatinglayer 133 is formed over the first insulating layer 131. Then, the thirdinsulating layer 133 and the first insulating layer 131 are subjected topolishing treatment or etching treatment until the surface of the secondregion 102 is exposed, so that the insulating layer 103 in which thesecond region 102 is in contact with the first region 101 and thesurface of the first region 101 and the surface of the second region 102are aligned with each other can be formed. Also in that case, the thirdinsulating layer 133 and the first insulating layer 131 may be etched byeither dry etching or wet etching.

Here, the second insulating layer 132 and the third insulating layer 133are formed; however, the second insulating layer 132 may be formed withthe use of the same material and the same method as those of the thirdinsulating layer 133, so that the second insulating layer 132 having aeven surface may be formed. In other words, as illustrated in FIG. 5A,the second insulating layer 132 having the even surface may be formedover the substrate 100 and the first region 101 with the use of the samematerial and the same method as those of the third insulating layer 133.The second insulating layer 132 having the even surface is subjected toetching treatment until the surface of the first region 101 is exposed,so that the second region 102 can be formed as illustrated in FIG. 5B.As a result, the insulating layer 103 in which the surface of the firstregion 101 and the surface of the second region 102 are aligned witheach other can be formed. Also in that case, the material used as thesecond region 102 is an insulating layer which releases a smaller amountof oxygen than the first region 101. Through the manufacturing methodillustrated in FIGS. 5A and 5B, the number of depositions for formingthe insulating layer 103 is smaller than that of the manufacturingmethod illustrated in FIGS. 4A to 4D and processing becomes easier.

The subsequent steps can be the same as those of FIG. 3A to 3D.

According to this embodiment, the first region 101 from which oxygen isreleased by heating is provided as an insulating layer in contact withthe channel region 126 of the oxide semiconductor layer 106, and thesecond region 102 which releases a smaller amount of oxygen than thefirst region 101 is provided as the insulating layer in contact with thesource region 122 a and the drain region 122 b of the oxidesemiconductor layer 106. As a result, a transistor having a smalloff-state current, small variation in the threshold voltage, a largeon-state current, and stable electrical characteristics can be provided.

According to this embodiment, a semiconductor device including a highlyreliable transistor having favorable electric characteristics isprovided.

The methods and structures described in this embodiment can be combinedas appropriate with any of the methods and structures described in theother embodiments.

Embodiment 2

In this embodiment, an embodiment of a semiconductor device will bedescribed with reference to FIG. 6. FIG. 6 illustrates a cross sectionof a transistor 156 having a structure which is different from that ofthe transistor 155 illustrated in FIG. 1A. The transistor 156illustrated in FIG. 6 is different from the transistor 155 illustratedin FIG. 1A in that the second region 102 is not provided.

The transistor 156 in FIG. 6 includes a first insulating layer 104, anoxide semiconductor layer 106, a gate insulating layer 112, and a gateelectrode 114, which are over a substrate 100. The transistor 156includes, in the oxide semiconductor layer 106, a channel region 126, asource region 122 a, and a drain region 122 b. The channel region 126,the source region 122 a, and the drain region 122 b are provided in thesame layer.

A second insulating layer 105 may be provided below the transistor 156.The second insulating layer 105 functions as a base layer of thetransistor 156.

The first insulating layer 104 is selectively provided over thesubstrate 100 or the second insulating layer 105 provided over thesubstrate 100. The oxide semiconductor layer 106 is provided over thefirst insulating layer 104. The oxide semiconductor layer 106 isprovided in contact with the first insulating layer 104 and thesubstrate 100 or the second insulating layer 105 provided over thesubstrate 100. The channel region 126 of the oxide semiconductor layer106 is provided in contact with the first insulating layer 104. Thesource region 122 a and the drain region 122 b of the oxidesemiconductor layer 106 are provided in contact with the substrate 100or the second insulating layer 105 provided over the substrate 100.

The gate insulating layer 112 is provided in contact with the oxidesemiconductor layer 106. The gate electrode 114 is provided in contactwith the gate insulating layer 112. An interlayer insulating layer 124is provided over the gate electrode 114. A wiring 108 a and a wiring 108b are electrically connected to the source region 122 a and the drainregion 122 b, respectively, through the interlayer insulating layer 124.The wiring 108 a and the wiring 108 b function as a source electrode anda drain electrode.

The material of the first insulating layer 104 can have the samestructure as the material of the first region 101 described inEmbodiment 1. In other words, as the material of the first insulatinglayer 104, silicon oxide, silicon oxynitride, aluminum oxide, a mixedmaterial of any of them, or the like may be used. Oxygen is releasedfrom the first insulating layer 104 by heating. To release oxygen byheating means that the released amount of oxygen which is converted tooxygen atoms is greater than or equal to 1×10¹⁸ atoms/cm³, preferablygreater than or equal to 3×10²⁰ atoms/cm³ in thermal desorptionspectroscopy (TDS). Alternatively, as the material of the firstinsulating layer 104, oxygen-excess silicon oxide (SiO_(X) (X>2)) may beused. In the oxygen-excess silicon oxide (SiO_(X) (X>2)), the number ofoxygen atoms per unit volume is more than twice the number of siliconatoms per unit volume. The number of silicon atoms and the number ofoxygen atoms per unit volume are measured by Rutherford backscatteringspectrometry.

In the case where the second insulating layer 105 is provided, thematerial of the second insulating layer 105 can have the same structureas the material of the second region 102 described in Embodiment 1. Inother words, as the material of the second insulating layer 105, siliconoxide, silicon nitride, silicon nitride oxide, silicon oxynitride,aluminum oxide, aluminum nitride, aluminum oxynitride, or the like maybe used. The second insulating layer 105 is an insulating layer whichreleases a smaller amount of oxygen than the first insulating layer 104.

In addition, the first insulating layer 104 and/or the second insulatinglayer 105 may be formed by stacking the above material and siliconoxide, silicon nitride, silicon oxynitride, silicon nitride oxide,aluminum oxide, aluminum nitride, aluminum oxynitride, a mixed materialthereof, or the like. In the case where the first insulating layer 104and/or the second insulating layer 105 are/is formed with a stackedstructure, a layer in contact with the oxide semiconductor layer 106 maybe formed using the material of the first insulating layer 104 or thematerial of the second insulating layer 105.

The channel region 126 and the first insulating layer 104 are in contactwith each other, whereby the interface state density between the firstinsulating layer 104 and the channel region 126 and oxygen deficiency inthe channel region 126 can be reduced. Owing to the reduction of theinterface state density, the shift of the threshold voltage in thenegative direction after a BT test can be suppressed. Alternatively,generation of carriers can be suppressed, so that normally-offcharacteristics can be obtained.

In addition, the source region 122 a and the drain region 122 b are incontact with the substrate 100 or the second insulating layer 105,whereby the increase of the resistance of the source region 122 a andthe drain region 122 b can be prevented, so that a semiconductor deviceincluding the highly reliable transistor 156 with good electricalcharacteristics can be provided.

There is no particular limitation on the property of a material and thelike of the substrate 100 as long as the material has heat resistanceenough to withstand at least heat treatment to be performed later. Forexample, a glass substrate, a ceramic substrate, a quartz substrate, ora sapphire substrate can be used as the substrate 100. Alternatively, asingle crystal semiconductor substrate or a polycrystallinesemiconductor substrate made of silicon, silicon carbide, or the like, acompound semiconductor substrate made of silicon germanium or the like,an SOI substrate, or the like may be used as the substrate 100. Stillalternatively, any of these substrates further provided with asemiconductor element may be used as the substrate 100.

A flexible substrate may alternatively be used as the substrate 100. Inthe case where a transistor is provided over the flexible substrate, thetransistor may be directly formed on the flexible substrate.Alternatively, the transistor may be formed over a different substrateand then separated to be transferred to the flexible substrate that isthe substrate 100. Note that in order to separate the transistor fromthe substrate and transfer it to the flexible substrate, a separationlayer is preferably formed between the different substrate and thetransistor.

Note that in the case where the second insulating layer 105 is notprovided, a substrate formed of a material which releases a smalleramount of oxygen than the first insulating layer 104 is preferably usedas the substrate 100. For example, in the case where the secondinsulating layer 105 is not provided, a glass substrate, a ceramicssubstrate, a quartz substrate, a sapphire substrate, an SOI substrate,or the like is preferably used as the substrate 100.

A manufacturing process of the transistor 156 is described. The secondinsulating layer 105 is formed over the entire surface of the substrate100 and the first insulating layer 104 is selectively formed over thesecond insulating layer 105. Oxygen is released from the firstinsulating layer 104 by heating. As the material of the first insulatinglayer 104, oxygen-excess silicon oxide (SiO_(X) (X>2)) may be used. Inorder to improve a coverage with the oxide semiconductor layer 106 to beformed later, the edge portion of the first insulating layer 104 ispreferably formed to have a slope. In addition, a photomask used in theformation of the first insulating layer 104 can be the same as thephotomask used in the formation of the gate electrode 114.

The subsequent steps can be the same as those described in Embodiment 1.

Since a step for aligning the surfaces of the insulating layers can beomitted in this embodiment, the transistor 156 can be provided by asimple method with low cost and high throughput.

According to this embodiment, the first insulating layer 104 from whichoxygen is released by heating is provided as an insulating layer incontact with the channel region 126 of the oxide semiconductor layer106, and the substrate 100 or the second insulating layer 105 whichreleases a smaller amount of oxygen than the first insulating layer 104is provided as a substrate or an insulating layer in contact with thesource region 122 a and the drain region 122 b of the oxidesemiconductor layer 106. As a result, a transistor having a smalloff-state current, small variation in the threshold voltage, a largeon-state current, and stable electrical characteristics can be provided.

According to this embodiment, a highly reliable semiconductor devicehaving good electric characteristics is provided.

The structures, methods, and the like described in this embodiment canbe combined as appropriate with any of the structures, methods, and thelike described in the other embodiments.

Embodiment 3

In this embodiment, an embodiment of a semiconductor device will bedescribed with reference to FIGS. 9A to 9C. FIG. 9A is a top view of atransistor. FIG. 9B illustrates a cross-sectional structurecorresponding to an alternate long and short dashed line A-B in FIG. 9A.

A transistor illustrated in FIG. 9B includes an insulating layer 103, anoxide semiconductor layer 136, a gate insulating layer 112, a gateelectrode 114, a sidewall insulating layer 130, a source electrode 116a, and a drain electrode 116 b over a substrate 100. The insulatinglayer 103 includes a first region 101 and a second region 102. Thetransistor illustrated in FIG. 9B includes a channel region 126, asource region 122 a, a drain region 122 b, an offset region 123 a, andan offset region 123 b in the oxide semiconductor layer 136. The channelregion 126, the source region 122 a, the drain region 122 b, the offsetregion 123 a, and the offset region 123 b are provided in the samelayer.

The offset region 123 a and the offset region 123 b have lowerresistance than the channel region 126 and have higher resistance thanthe source region 122 a and the drain region 122 b. The width of theoffset region 123 a or the offset region 123 b is also referred to asLoff, which is illustrated in FIG. 9A. With the Loff, a short-channeleffect of the transistor is reduced. Therefore, in the case of using aminute transistor in which a short-channel effect is notably enhanced,the structure illustrated in FIG. 9B (also referred to as a Loffstructure) is favorable. In addition, by employing the Loff structure,degradation of the transistor, such as hot-carrier degradation, can bereduced.

The oxide semiconductor layer 136 is provided in contact with the firstregion 101 and the second region 102. The channel region 126 of theoxide semiconductor layer 136 is provided in contact with the firstregion 101. The source region 122 a, the drain region 122 b, the offsetregion 123 a, and the offset region 123 b are provided in contact withthe second region 102. The offset region 123 a and the offset region 123b are closer to the channel region 126 than the source region 122 a andthe drain region 122 b are.

The gate insulating layer 112 is provided in contact with the channelregion 126, the offset region 123 a, and the offset region 123 b. Thesidewall insulating layer 130 is provided in the periphery of the gateelectrode 114. The gate electrode 114 and the sidewall insulating layer130 are provided in contact with the gate insulating layer 112. Aninterlayer insulating layer 124 is provided over the gate electrode 114and the sidewall insulating layer 130. The source electrode 116 a andthe drain electrode 116 b are provided in contact with the source region122 a and the drain region 122 b, respectively. A wiring 108 a and awiring 108 b are electrically connected to the source electrode 116 aand the drain electrode 116 b through the interlayer insulating layer124.

As a conductive layer used for the source electrode 116 a and the drainelectrode 116 b, for example, a metal layer containing an elementselected from Al, Cr, Cu, Ta, Ti, Mo, and W, or a metal nitride layercontaining any of the above elements as its component (e.g., a titaniumnitride layer, a molybdenum nitride layer, or a tungsten nitride layer)can be used. A high-melting-point metal layer of Ti, Mo, W, or the likeor a metal nitride layer of any of these elements (a titanium nitridelayer, a molybdenum nitride layer, or a tungsten nitride layer) may bestacked on one of or both a bottom side and a top side of a metal layerof Al, Cu, or the like.

In addition, the offset region 123 a and the offset region 123 b areprovided in contact with the second region 102 which releases a smalleramount of oxygen than the first region 101, so that oxygen is notsupplied to the offset region 123 a and the offset region 123 b.

The offset region 123 a and the offset region 123 b are not regionswhose resistance is particularly reduced, and are distinguished from thechannel region 126 depending on which region of the insulating layer 103is in contact with the offset region 123 a and the offset region 123 b.That is, the offset region 123 a and the offset region 123 b are regionsof the oxide semiconductor layer 136 which are not in contact with theinsulating layer from which oxygen is released by heating.

The transistor described in this embodiment includes the offset regions,whereby the highly reliable transistor having better electricalcharacteristics can be provided.

Note that the offset regions are not necessarily provided. For example,a transistor illustrated in FIG. 9C has a different structure from thetransistor of FIG. 9B in that offset regions are not provided.

According to this embodiment, a semiconductor device including a highlyreliable transistor having good electrical characteristics can beprovided.

The structures, methods, and the like described in this embodiment canbe combined as appropriate with any of the structures, methods, and thelike described in the other embodiments.

Embodiment 4

A semiconductor device having a display function (also referred to as adisplay device) can be manufactured using the transistor described inEmbodiment 1, Embodiment 2, or Embodiment 3. Moreover, some or all ofthe driver circuits which include the transistor can be formed over asubstrate where the pixel portion is formed, whereby a system-on-panelcan be obtained.

In FIG. 7A, a sealant 205 is provided so as to surround a pixel portion202 provided over a first substrate 201, and the pixel portion 202 issealed with the sealant 205 between the first substrate 201 and a secondsubstrate 206. In FIG. 7A, a scan line driver circuit 204 and a signalline driver circuit 203 each are formed using a single crystalsemiconductor layer or a polycrystalline semiconductor layer over asubstrate prepared separately, and mounted in a region different fromthe region surrounded by the sealant 205 over the first substrate 201.Various signals and potentials are supplied to the signal line drivercircuit 203 and the scan line driver circuit 204, each of which isseparately formed, and the pixel portion 202, from flexible printedcircuits (FPCs) 218 a and 218 b.

In FIGS. 7B and 7C, the sealant 205 is provided to surround the pixelportion 202 and the scan line driver circuit 204 which are provided overthe first substrate 201. The second substrate 206 is provided over thepixel portion 202 and the scan line driver circuit 204. Thus, the pixelportion 202 and the scan line driver circuit 204 are sealed togetherwith a display element, by the first substrate 201, the sealant 205, andthe second substrate 206. In FIGS. 7B and 7C, the signal line drivercircuit 203 is formed using a single crystal semiconductor layer or apolycrystalline semiconductor layer over a substrate preparedseparately, and mounted in a region different from the region surroundedby the sealant 205 over the first substrate 201. In FIGS. 7B and 7C,various signals and potentials are supplied from a FPC 218 to the signalline driver circuit 203 which is separately formed, the scan line drivercircuit 204, and the pixel portion 202.

Although FIGS. 7B and 7C each show the example in which the signal linedriver circuit 203 is formed separately and mounted on the firstsubstrate 201, one embodiment of the present invention is not limited tothis structure. The scan line driver circuit may be formed separatelyand then mounted, or only part of the signal line driver circuit or partof the scan line driver circuit may be formed separately and thenmounted.

Note that a connection method of a separately formed driver circuit isnot particularly limited, and a chip on glass (COG) method, a wirebonding method, a tape automated bonding (TAB) method or the like can beused. FIG. 7A shows an example in which the signal line driver circuit203 and the scan line driver circuit 204 are mounted by a COG method.FIG. 7B shows an example in which the signal line driver circuit 203 ismounted by a COG method. FIG. 7C shows an example in which the signalline driver circuit 203 is mounted by a TAB method.

The display device includes in its category a panel in which a displayelement is sealed and a module in which an IC such as a controller ismounted on the panel.

Note that a display device in this specification means an image displaydevice, a display device, or a light source (including a lightingdevice). The display device includes any of the following modules: amodule provided with a connector such as an FPC, a TAB tape, or TCP; amodule in which a printed wiring board is provided in the end of a TABtape or TCP; and a module in which an integrated circuit (IC) is mounteddirectly on a display element by a COG method.

Further, the pixel portion and the scan line driver circuit which areprovided over the first substrate 201 include a plurality oftransistors, to which the transistor whose example is described inEmbodiment 1, Embodiment 2, or Embodiment 3 can be applied.

As the display element provided in the display device, a liquid crystalelement (also referred to as a liquid crystal display element) or alight-emitting element (also referred to as a light-emitting displayelement) can be used. A light-emitting element includes, in itscategory, an element whose luminance is controlled by current orvoltage, and specifically an inorganic electroluminescent (EL) element,an organic EL element, and the like. Furthermore, a display medium whosecontrast is changed by an electric effect, such as electronic ink, canbe used.

In the case where a liquid crystal element is used as the displayelement, a thermotropic liquid crystal, a low-molecular liquid crystal,a high-molecular liquid crystal, a polymer dispersed liquid crystal, aferroelectric liquid crystal, an anti-ferroelectric liquid crystal, orthe like can be used. Such a liquid crystal material exhibits acholesteric phase, a smectic phase, a cubic phase, a chiral nematicphase, an isotropic phase, or the like depending on conditions.

Alternatively, a liquid crystal exhibiting a blue phase for which analignment layer is unnecessary may be used. A blue phase is one ofliquid crystal phases, which is generated just before a cholestericphase changes into an isotropic phase while temperature of cholestericliquid crystal is increased. Since the blue phase appears only in anarrow temperature range, a liquid crystal composition in which a chiralmaterial is mixed is used for the liquid crystal layer in order toimprove the temperature range. The liquid crystal composition whichincludes a liquid crystal exhibiting a blue phase and a chiral agent hasa short response time of 1 msec or less, has optical isotropy, whichmakes the alignment process unneeded, and has a small viewing angledependence. In addition, since an alignment layer does not need to beprovided and rubbing treatment is unnecessary, electrostatic dischargedamage caused by the rubbing treatment can be prevented and defects anddamage of the liquid crystal display device can be reduced in themanufacturing process. Thus, productivity of the liquid crystal displaydevice can be increased.

The specific resistivity of the liquid crystal material is 1×10⁹ Ω·cm ormore, preferably 1×10¹¹ Ω·cm or more, more preferably 1×10¹² Ω·cm ormore. The value of the specific resistivity in this specification ismeasured at 20° C.

The size of a storage capacitor provided in the liquid crystal displaydevice is set in consideration of the leakage current of the transistorprovided in the pixel portion or the like so that a charge can be heldfor a predetermined period. By using a transistor including ahigh-purity oxide semiconductor layer, it is enough to provide a storagecapacitor having a capacitance that is less than or equal to ⅓,preferably less than or equal to ⅕ of a liquid crystal capacitance ofeach pixel.

In the transistor including an oxide semiconductor layer used in thisembodiment, the current in an off state (the off-state current) can bemade small. Therefore, an electrical signal such as an image signal canbe held for a long period, and a writing interval can be set long whenthe power is on. Accordingly, frequency of refresh operation can bereduced, which leads to an effect of suppressing power consumption.

The field-effect mobility of the transistor including an oxidesemiconductor layer used in this embodiment can be relatively high,whereby high-speed operation is possible. Therefore, by using thetransistor in a pixel portion of a liquid crystal display device, ahigh-quality image can be provided. In addition, since the transistorscan be separately provided in a driver circuit portion and a pixelportion over one substrate, the number of components of the liquidcrystal display device can be reduced.

For the liquid crystal display device, a twisted nematic (TN) mode, anin-plane-switching (IPS) mode, a fringe field switching (FFS) mode, anaxially symmetric aligned micro-cell (ASM) mode, an optical compensatedbirefringence (OCB) mode, a ferroelectric liquid crystal (FLC) mode, anantiferroelectric liquid crystal (AFLC) mode, or the like can be used.

A normally black liquid crystal display device such as a transmissiveliquid crystal display device utilizing a vertical alignment (VA) modeis preferable. The vertical alignment mode is a method of controllingalignment of liquid crystal molecules of a liquid crystal display panel,in which liquid crystal molecules are aligned vertically to a panelsurface when no voltage is applied. Some examples are given as thevertical alignment mode. For example, a multi-domain vertical alignment(MVA) mode, a patterned vertical alignment (PVA) mode, an advanced superview (ASV) mode, and the like can be used. Moreover, it is possible touse a method called domain multiplication or multi-domain design, inwhich a pixel is divided into some regions (subpixels) and molecules arealigned in different directions in their respective regions.

In the display device, a black matrix (a light-blocking layer), anoptical member (an optical substrate) such as a polarizing member, aretardation member, or an anti-reflection member, and the like areprovided as appropriate. For example, circular polarization may beobtained by using a polarizing substrate and a retardation substrate. Inaddition, a backlight, a side light, or the like may be used as a lightsource.

In addition, it is possible to employ a time-division display method(also called a field-sequential driving method) with the use of aplurality of light-emitting diodes (LEDs) as a backlight. By employing afield-sequential driving method, color display can be performed withoutusing a color filter.

As a display method in the pixel portion, a progressive method, aninterlace method, or the like can be employed. Further, color elementscontrolled in a pixel at the time of color display are not limited tothree colors: R, G, and B (R, G, and B correspond to red, green, andblue, respectively). For example, R, G, B, and W (W corresponds towhite), or R, G, B, and one or more of yellow, cyan, magenta, and thelike can be used. Further, the sizes of display regions may be differentbetween respective dots of color elements. An embodiment of the presentinvention is not limited to the application to a display device forcolor display but can also be applied to a display device for monochromedisplay.

Alternatively, as the display element included in the display device, alight-emitting element utilizing electroluminescence can be used.Light-emitting elements utilizing electroluminescence are classifiedaccording to whether a light-emitting material is an organic compound oran inorganic compound. In general, the former is referred to as anorganic EL element, and the latter is referred to as an inorganic ELelement.

In an organic EL element, by application of a voltage to alight-emitting element, electrons and holes are separately injected froma pair of electrodes into a layer containing a light-emitting organiccompound, so that current flows. The carriers (electrons and holes) arerecombined, and thus the light-emitting organic compound is excited. Thelight-emitting organic compound returns to a ground state from theexcited state, thereby emitting light. Owing to such a mechanism, thislight-emitting element is referred to as a current-excitationlight-emitting element.

The inorganic EL elements are classified according to their elementstructures into a dispersion-type inorganic EL element and a thin-filminorganic EL element. A dispersion-type inorganic EL element has alight-emitting layer where particles of a light-emitting material aredispersed in a binder, and its light emission mechanism isdonor-acceptor recombination type light emission that utilizes a donorlevel and an acceptor level. A thin-film inorganic EL element has astructure where a light-emitting layer is sandwiched between dielectriclayers, which are further sandwiched between electrodes, and its lightemission mechanism is localized type light emission that utilizesinner-shell electron transition of metal ions. Note that an example ofan organic EL element as a light-emitting element is described here.

In order to extract light emitted from the light-emitting element, it isacceptable as long as at least one of a pair of electrodes istransparent. The light-emitting element can have a top emissionstructure in which light emission is extracted through the surfaceopposite to the substrate; a bottom emission structure in which lightemission is extracted through the surface on the substrate side; or adual emission structure in which light emission is extracted through thesurface opposite to the substrate and the surface on the substrate side,and a light-emitting element having any of these emission structures canbe used.

Further, an electronic paper in which electronic ink is driven can beprovided as the display device. The electronic paper is also called anelectrophoretic display device (electrophoretic display) and hasadvantages in that it has the same level of readability as regularpaper, it has less power consumption than other display devices, and itcan be set to have a thin and light form.

An electrophoretic display device can have various modes. Anelectrophoretic display device contains a plurality of microcapsulesdispersed in a solvent or a solute, each microcapsule containing firstparticles which are positively charged and second particles which arenegatively charged. By applying an electric field to the microcapsules,the particles in the microcapsules move in opposite directions to eachother and only the color of the particles gathering on one side isdisplayed. Note that the first particles and the second particles eachcontain pigment and do not move without an electric field. Moreover, thefirst particles and the second particles have different colors (whichmay be colorless).

Thus, an electrophoretic display device is a display device thatutilizes a so-called dielectrophoretic effect by which a substancehaving a high dielectric constant moves to a high-electric field region.

A solution in which the above microcapsules are dispersed in a solventis referred to as electronic ink. This electronic ink can be printed ona surface of glass, plastic, cloth, paper, or the like. Furthermore, byusing a color filter or particles that have a pigment, color display canalso be achieved.

Note that the first particles and the second particles in themicrocapsules may each be formed of a single material selected from aconductive material, an insulating material, a semiconductor material, amagnetic material, a liquid crystal material, a ferroelectric material,an electroluminescent material, an electrochromic material, and amagnetophoretic material, or formed of a composite material thereof.

As the electronic paper, a display device using a twisting ball displaysystem can be used. The twisting ball display system refers to a methodin which spherical particles each colored in black and white arearranged between a first electrode layer and a second electrode layerwhich are electrode layers used for a display element, and a potentialdifference is generated between the first electrode layer and the secondelectrode layer to control orientation of the spherical particles, sothat display is performed.

The display device performs display by transmitting light from a lightsource or a display element. Therefore, the substrate and the thin filmssuch as the insulating layer and the conductive layer provided for thepixel portion where light is transmitted have light-transmittingproperties with respect to light in the visible-light wavelength range.

The first electrode layer and the second electrode layer (each of whichmay be called a pixel electrode layer, a common electrode layer, acounter electrode layer, or the like) for applying voltage to thedisplay element may have light-transmitting properties orlight-reflecting properties, which depends on the direction in whichlight is extracted, the position where the electrode layer is provided,the pattern structure of the electrode layer, and the like.

As described above, by using any of the transistors exemplified inEmbodiment 1, Embodiment 2 or Embodiment 3, the highly reliablesemiconductor device can be provided. Note that the transistorsdescribed in Embodiment 1, Embodiment 2 or Embodiment 3 can be appliedto not only semiconductor devices having the display functions describedabove but also semiconductor devices having a variety of functions, suchas a power device which is mounted on a power supply circuit, asemiconductor integrated circuit such as an LSI, and a semiconductordevice having an image sensor function of reading information of anobject.

The structures, methods, and the like described in this embodiment canbe combined as appropriate with any of the structures, methods, and thelike described in the other embodiments.

Embodiment 5

A semiconductor device that is one embodiment of the present inventioncan be applied to a variety of electronic appliances (including gamemachines). Examples of electronic appliances are a television set (alsoreferred to as a television or a television receiver), a monitor of acomputer or the like, a camera such as a digital camera or a digitalvideo camera, a digital photo frame, a mobile phone handset (alsoreferred to as a mobile phone or a mobile phone device), a portable gamemachine, a portable information terminal, an audio reproducing device,and a large-sized game machine such as a pachinko machine. Examples ofelectronic appliances each including the semiconductor device describedin the above embodiment will be described.

FIG. 8A illustrates a laptop personal computer which includes a mainbody 301, a housing 302, a display portion 303, a keyboard 304, and thelike. The semiconductor device described in any of Embodiments 1 to 4 isused, whereby a highly reliable laptop personal computer can beprovided.

FIG. 8B illustrates a personal digital assistant (PDA) which includes amain body 311 provided with a display portion 313, an external interface315, an operation button 314, and the like. A stylus 312 is included asan accessory for operation. The semiconductor device described in any ofEmbodiments 1 to 4 is used, whereby the highly reliable personal digitalassistant (PDA) can be provided.

FIG. 8C illustrates an example of an e-book reader. For example, ane-book reader 320 includes two housings, a housing 321 and a housing322. The housing 321 and the housing 322 are combined with a hinge 325so that the e-book reader 320 can be opened and closed with the hinge325 as an axis. With such a structure, the e-book reader 320 can operatelike a paper book.

A display portion 323 and a display portion 324 are incorporated in thehousing 321 and the housing 322, respectively. The display portion 323and the display portion 324 may display one image or different images.When the display portion 323 and the display portion 324 displaydifferent images, for example, text can be displayed on a displayportion on the right side (the display portion 323 in FIG. 8C) andgraphics can be displayed on a display portion on the left side (thedisplay portion 324 in FIG. 8C). The semiconductor device described inany of Embodiments 1 to 4 is used, whereby the highly reliable e-bookreader can be provided.

FIG. 8C illustrates an example in which the housing 321 is provided withan operation portion and the like. For example, the housing 321 isprovided with a power switch 326, operation keys 327, a speaker 328, andthe like. With the operation keys 327, pages can be turned. Note that akeyboard, a pointing device, or the like may also be provided on asurface of the housing, on which the display portion is provided.Furthermore, an external connection terminal (an earphone terminal, aUSB terminal, or the like), a recording medium insertion portion, andthe like may be provided on the back surface or the side surface of thehousing. Further, the e-book reader 320 may have a function of anelectronic dictionary.

The e-book reader 320 may send and receive data wirelessly. Throughwireless communication, desired book data or the like can be purchasedand downloaded from an electronic book server.

FIG. 8D illustrates a portable information terminal, which includes twohousings, a housing 330 and a housing 331. The housing 331 includes adisplay panel 332, a speaker 333, a microphone 334, a pointing device336, a camera lens 337, an external connection terminal 338, and thelike. In addition, the housing 330 includes a solar cell 340 having afunction of charge of the portable information terminal, an externalmemory slot 341, and the like. Further, an antenna is incorporated inthe housing 331. The semiconductor device described in any ofEmbodiments 1 to 4 is used, whereby the highly reliable portableinformation terminal can be provided.

Further, the display panel 332 is provided with a touch panel. Aplurality of operation keys 335 which are displayed as images isillustrated by dashed lines in FIG. 8D. Note that the mobile phoneincludes a boosting circuit for raising a voltage output from the solarcell 340 to a voltage necessary for each circuit.

In the display panel 332, the display direction can be changed asappropriate depending on a usage pattern. Further, the mobile phone isprovided with the camera lens 337 on the same surface as the displaypanel 332, and thus it can be used as a video phone. The speaker 333 andthe microphone 334 can be used for videophone calls, recording andplaying sound, and the like as well as voice calls. Moreover, thehousings 330 and 331 in a state where they are opened as illustrated inFIG. 8D can be slid so that one overlaps the other; therefore, the sizeof the mobile phone can be reduced, which makes the mobile phonesuitable for being carried.

The external connection terminal 338 can be connected to an AC adapterand various types of cables such as a USB cable, and charging and datacommunication with a personal computer are possible. Moreover, a largeramount of data can be stored by inserting a recording medium to theexternal memory slot 341 and can be moved.

Further, in addition to the above functions, an infrared communicationfunction, a television reception function, or the like may be provided.

FIG. 8E illustrates a digital video camera, which includes a main body351, a display portion A 357, an eyepiece 353, an operation switch 354,a display portion B 355, a battery 356, and the like. The semiconductordevice described in any of Embodiments 1 to 4 is used, whereby thehighly reliable digital video camera can be provided.

FIG. 8F illustrates an example of a television set. In a television set360, a display portion 363 is incorporated in a housing 361. The displayportion 363 can display images. Here, the housing 361 is supported by astand 365. The semiconductor device described in any of Embodiments 1 to4 is used, whereby the highly reliable television set 360 can beprovided.

The television set 360 can be operated by an operation switch of thehousing 361 or a separate remote controller. Further, the remotecontroller may be provided with a display portion for displaying dataoutput from the remote controller.

Note that the television set 360 is provided with a receiver, a modem,and the like. With the use of the receiver, general televisionbroadcasting can be received. Moreover, when the television set isconnected to a communication network with or without wires via themodem, one-way (from a sender to a receiver) or two-way (between asender and a receiver or between receivers) information communicationcan be performed.

The structures, methods, and the like described in this embodiment canbe combined as appropriate with any of the structures, methods, and thelike described in the other embodiments.

This application is based on Japanese Patent Application serial no.2010-167383 filed with Japan Patent Office on Jul. 26, 2010, the entirecontents of which are hereby incorporated by reference.

1. (canceled)
 2. A method for manufacturing a semiconductor device,comprising the steps of: forming an insulating layer including a firstregion and a second region; forming an oxide semiconductor layer incontact with the first region and the second region; forming a gateinsulating layer in contact with the oxide semiconductor layer; forminga gate electrode in contact with the gate insulating layer; forming asource region and a drain region in the oxide semiconductor layer byreducing resistance of a part of the oxide semiconductor layer to be incontact with the second region; and forming a channel region in theoxide semiconductor layer to be in contact with the first region,wherein a composition of the first region is different from acomposition of the second region.
 3. The method for manufacturing asemiconductor device according to claim 2, wherein the first regioncomprises silicon oxide, and wherein the second region comprises siliconoxide, silicon nitride, silicon nitride oxide, silicon oxynitride,aluminum oxide, aluminum nitride, or aluminum oxynitride.
 4. The methodfor manufacturing a semiconductor device according to claim 2, whereinthe first region is formed by a sputtering method.
 5. The method formanufacturing a semiconductor device according to claim 2, wherein asurface of the first region and a surface of the second region arecoplanar with each other.
 6. The method for manufacturing asemiconductor device according to claim 2, wherein the oxidesemiconductor layer is formed by a sputtering method.
 7. The method formanufacturing a semiconductor device according to claim 2, wherein heattreatment at a temperature higher than or equal to 100° C. and lowerthan or equal to 650° C. is performed after the oxide semiconductorlayer is formed.
 8. The method for manufacturing a semiconductor deviceaccording to claim 2, wherein the source region and the drain region areformed in the oxide semiconductor layer by reducing resistance of a partof the oxide semiconductor layer with the use of the gate electrode as amask, and the channel region is formed in a part of the oxidesemiconductor layer which is covered with the gate electrode.
 9. Themethod for manufacturing a semiconductor device according to claim 2,further comprising the steps of: forming an interlayer insulating layerover the gate electrode, and forming a wiring over the interlayerinsulating layer and in contact with the oxide semiconductor layerthrough an opening provided in the interlayer insulating layer.
 10. Themethod for manufacturing a semiconductor device according to claim 2,wherein the first region comprises silicon oxide in which the number ofoxygen atoms is more than twice the number of silicon atoms per unitvolume, and wherein the second region comprises silicon oxide or siliconoxynitride whose number of oxygen atoms per unit volume is smaller thanthe number of oxygen atoms per unit volume of the first region.
 11. Themethod for manufacturing a semiconductor device according to claim 2,wherein oxygen is released from the insulating layer and the gateinsulating layer by heating.
 12. The method for manufacturing asemiconductor device according to claim 2, wherein the insulating layerand the gate insulating layer comprise silicon oxide in which the numberof oxygen atoms is more than twice the number of silicon atoms per unitvolume.
 13. The method for manufacturing a semiconductor deviceaccording to claim 2, wherein an amount of oxide deficiency in thechannel region is lower than in the source region and the drain region.14. The method for manufacturing a semiconductor device according toclaim 2, wherein the first region contains oxygen at a higherconcentration than the second region.
 15. A method for manufacturing asemiconductor device, comprising the steps of: selectively forming aninsulating layer on an insulating surface; forming an oxidesemiconductor layer to extend beyond side surfaces of the insulatinglayer; forming a gate insulating layer in contact with the oxidesemiconductor layer; forming a gate electrode in contact with the gateinsulating layer; forming a source region and a drain region in theoxide semiconductor layer by reducing resistance of part of the oxidesemiconductor layer to be in contact with the insulating surface; andforming a channel region in the oxide semiconductor layer to be incontact with the insulating layer.
 16. The method for manufacturing asemiconductor device according to claim 15, wherein the insulating layercomprises silicon oxide.
 17. The method for manufacturing asemiconductor device according to claim 15, wherein the insulating layeris formed by a sputtering method using oxygen or a mixed gas of oxygenand argon.
 18. The method for manufacturing a semiconductor deviceaccording to claim 15, wherein the oxide semiconductor layer is formedby a sputtering method.
 19. The method for manufacturing a semiconductordevice according to claim 15, wherein heat treatment at a temperaturehigher than or equal to 100° C. and lower than or equal to 650° C. isperformed after the oxide semiconductor layer is formed.
 20. The methodfor manufacturing a semiconductor device according to claim 15, whereinthe source region and the drain region are formed in the oxidesemiconductor layer by reducing resistance of part of the oxidesemiconductor layer with the use of the gate electrode as a mask, andthe channel region is formed in part of the oxide semiconductor layerwhich is covered with the gate electrode.
 21. The method formanufacturing a semiconductor device according to claim 15, furthercomprising the steps of: forming an interlayer insulating layer over thegate electrode, and forming a wiring over the interlayer insulatinglayer and in contact with the oxide semiconductor layer through anopening provided in the interlayer insulating layer.
 22. The method formanufacturing a semiconductor device according to claim 15, whereinoxygen is released from the insulating layer and the gate insulatinglayer by heating.
 23. The method for manufacturing a semiconductordevice according to claim 15, wherein the insulating layer and the gateinsulating layer comprise silicon oxide in which the number of oxygenatoms is more than twice the number of silicon atoms per unit volume.24. The method for manufacturing a semiconductor device according toclaim 15, wherein an amount of oxide deficiency in the channel region islower than in the source region and the drain region.